Instead of paying 50+ for light mounts, how can one make some for a surco roof rack...
also, I do not have a welder, but can take it to the place that welded my muffler and I'm sure he'd do it for pretty cheap.

welding to aluminum is difficult and generally not cheap... im no pro welder but im pretty sure thats the case

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08 Revenge- Rock Lizard (Skink Sliders & Gecko Roof Rails), High Clearance Trimmed Front Bumper, Mopar skids, Riddler Diff Cover, JBA (5.5 Arms, 6" rear Springs, Front Adjust-A-Struts), 32" DuraTracs, Superior 4.56's, Front & Rear ARB Lockers, Fastman Throttle Body, AEM Intake, Hypertech Tune, Custom Ram Air, RunCool Louvers

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2006 Liberty Renegade
OME, Rancho, RRO A arms, RRO roof rails w/ diy cross bars, Dual XHD7714 with Pyle speakers, drop in K&N air filter with home made CAI, 8k smittybilt winch , Sears Platinum P1, in cab winch control, 100w Optilux lights, 7" e-code Hella headlights,245/75-16C Duratracs. DIY rockrails, DIY rear double deck cargo rack.

You could drill some holes and install some blind hole nuts such as these:
http://www.blindrivetsupply.com/Steel_c_55.html

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2006 Liberty Renegade
OME, Rancho, RRO A arms, RRO roof rails w/ diy cross bars, Dual XHD7714 with Pyle speakers, drop in K&N air filter with home made CAI, 8k smittybilt winch , Sears Platinum P1, in cab winch control, 100w Optilux lights, 7" e-code Hella headlights,245/75-16C Duratracs. DIY rockrails, DIY rear double deck cargo rack.

I just got the 4560 Surco myself and I was thinking of basically using L brackets bent so that one part of the L fits around the tubing of the rack (ruler, hammer and vice work nicely here) and then attach with pop rivets or drill through and use some good screws with nuts and lock washers to attach them to the rack.

If I could draw, I'd send you a crude sketch of my idea. But honestly, I'm not sure yet if I'm going to keep the rack at all so I'm not in a rush to do the light tabs. You might keep an eye out on craigslist and such for the brackets, they may pop up.

JIC I keep it, post back with whatever you come up with, I'd like to see it...!

Good luck,
MojaveKJ

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'13 Wrangler Unlimited Rubicon, Trasharoo, Husky liners, Skid Row plates, Ursa Minor J30, Expedition One rear bumper & tire carrier, Rugged Ridge CB antenna mount, SuperStar 4900+ transceiver, iPad Mini with MotionX GPS.